References :

http://www.ncspa.org/calculators-charts-and-tools/213-lifecycle-cost-analysis-and-calculator.html
http://textilelearner.blogspot.in/2013/03/straight-knife-cutting-machine-with.html
Eastman Blue Streak II Hand manual

Maintenance
Management
Maintenance Scheduling & Life Cycle Costing for
Straight Knife Cutting Machine
Assignment - II

NIFT,Kangra
Prepared By:
Abhishek Kumar
Anmol Jain
Himanshu Dixit
(D.F.T-VI)

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Straight Knife cutting machine

In apparel industry, more than 99% cases this knife is used. This machine is
called straight knife cutting machine because its cutter is straight in shape. It is
used for both woven & knit fabric. In this machine different types of straight knife
are used according to the different cutting objects. This machine provides good
efficiency.

Features of Straight Knife Cutting

Machine

The main parts of this machine are straight knife, electric motor, handle,
grinder, base plate, stand/ knife holder, lubricating unit, wheel etc.
Could be used to cut higher depth of fabric.
Knife height is 10 cm to 33 cm.
Knife stroke is 2.5 cm to 4.5 cm.
Motor r.p.m. is 3000 to 4000.
Auto grinder is used.
Auto lubricating unit works for this machine.
Different types of knife edge are used for cutting different objects. Such
as, straight edge, wave edge, sew edge & serrated edge.
A Handle for the cutter to direct the Knife.
Knife guard is attached to the front of the knife.
Sharp & heavy corners can be cut.
Maximum 70% of knife height is used for fabric lay.
Wheels are under the base plate to move the machine smoothly.
Machine weight is around 12-15 kg.
Knife cut the fabric very fast due to high speed of motor. That increases
the risk of fabric damage.

M/C description
The elements of a straight knife consists of

A base plate Usually in rollers for easy movement.

An electric motor.
Handle for the cutter to direct the blade.
Knife (Reciprocating motion).
Knife guard.

Grinding wheel used to sharp the knife during cutting.

Stand.
Roller wheel to move the machine over cutting table easily.

Working principle
Two kind of power are required to operate a straight knife.

Motor power drives the reciprocating blade.

Operator power drives the knife through the lay.

The motor power needed is determined by

Height of the lay.

The construction of the fabric.
The curvature of the line being cut.
The stroke of the blade.

Maintenance of straight knife

cutter
Machines condition will be deteriorated if it is exposed to the environment and
subject to use. If these process remain unchecked and unchanged it will cause
unserviceable and standstill of the machine. Industry therefore has no other way
but to attend, to repair, to maintain, to set and to recondition them so as to
prolong their life to the extent it is economically and physically possible to do so.
So according to engineering aspect respects repair, maintenance, setting and
replacement of different parts of the machines are badly needed and so on.

Required Tools

Flat screw driver

Star screw driver
Hammer
Pliers
Lubricating oil
Grease

Repair
Repair work is carried out when a component requires slight modification. To
carry out such job the machine needs to be switched off first. The component

under repairing, the part is fixed to its designed place and hence its correction is
measured by running the machine. In a straight knife cutting machine motor,
knife, knife guard, wheel, base plate wheel controller, can undergo repair job.

Maintenance types required

Routine maintenance: Lubrication and regular inspection are the

constituents of routine maintenance. Lubrication ensures long life and safe
working of all the equipment. Inspection tries to detect fault in equipment
so that repairs and replacement may be undertake at right time.
Scheduled maintenance: This type of maintenance provides for inspection,
overhaul lubrication and servicing of the machine at predetermined dates.
Overhauling of machine, cleaning of all components is normally done in
this manner. It involves opening of the machine into its smallest
components and carry out lubrication.

Manual Setting
The setting of the machine is of immense importance. Following setting points
need to be ensured before running the machine.

Knife: In straight knife cutting machine, the knife is straight and it has
reciprocating motor. The height of blade ranges from 1.-33 cm and the
stroke of blade ranges from 2.4 - 4.5 cm. The setting of knife is very
important. For smooth cutting, the knife maintenance is very necessary.
Sharp edge of straight knife: The sharp edge knife may have various
shapes for various extent of cutting. Such as, to cut soft and fine lay of
fabric, straight edge is used to cut canvas fabric, sew edge is used to cut
coarse and heavy cotton fabric, serrated edge is used. So, the sharp edge
of knife should be selected according to requirements.
Motor: Motor rpm expresses the speed of the machine. In straight knife
cutting machine, two types of force are required i.e. for the reciprocating
motion of straight knife and for the movement of knife inside the lay of
fabric. The rpm is controlled by regulator of motor and the movement of
knife inside the lay of fabric.
Fabric height controller: Fabric height can be controlled by controlling the
height of blade. Fabric height should be controlled depending on types of
fabric, cutting efficiency, requirement etc.

Replacement
The replacement is revealed when the retention on equipment is no more
remains an economical proportion. A replacement is affected when the
equipment is subjected to complete breakage which cannot be used even after
repair or the component has become so obsolete that affects production or it has
crossed its expire date. Replacement can be affected to any components of the
machine at any time. In straight knife cutting machine, main component knife

undergo frequent replacement. The grinding wheel, base plate wheel need not to
replace very frequently, but they need to be replaced for proper function of
machine.

Maintenance Schedule
09:00:00
10:00:00
11:00:00
12:00:00
13:00:00
14:00:00
15:00:00
16:00:00
17:00:00
18:00:00

01-052015
02-052015
03-052015
04-052015
05-052015
06-052015
07-052015
08-052015

Oil Check

Oil Check

Clean
Sharpener

Clean
Sharpener

Maintenance schedule
Daily Schedule
Clean blades
Dry Run

Clean blades

Dry Run

Maintenance schedule
Weekly Schedule
Clean Oil gears under base
Change Blades plate

Change Blades

Clean Oil gears under base

plate

Maintenance schedule
Semi - Annually Schedule
May15
Jun-15
Jul-15
Aug15
Sep15
Oct-15
Nov15
Dec15
Jan-16
Feb-16

Clean Carbon Brushes

Calibrate
Check Commuter Gears

Clean
Rollers

Clean Carbon Brushes

Calibrate
Check Commuter Gears

Clean
Rollers

Maintenance schedule
Monthly Schedule
May15
Jun-15
Jul-15
Aug15
Sep15
Oct-15
Nov15
Dec15

Clean Motors
Clean Motors
Clean Motors

Clean Gears
Clean Gears
Clean Gears

Basic Servicing
Basic Servicing
Basic Servicing

Clean Motors

Clean Gears

Basic Servicing

Clean Motors
Clean Motors

Clean Gears
Clean Gears

Basic Servicing
Basic Servicing

Clean Motors

Clean Gears

Basic Servicing

Clean Motors

Clean Gears

Basic Servicing

Life Cycle Costing

Machine Initial Cost ( Machine Cost + Setup) = 26000 INR

Life in hours (6yrs.) = 15000 hrs
Annual Usage (hrs) = 2500
Annual Major Cost (Blade & Spares) = 1200* 160 =
192000 (1200 per blade , changed every two days)
Annual Servicing = 40000
Total Cost For 6 Years : 2,58,000 INR